1979 DATSUN 210 Service Manual

DATSUN

210
Model
8310
Series

MANUAL
TRANSMISSION

CONTENTS

4
SPEED
TRANSMISSION

Model
F4W60L

REMOVAL

INSTALLATION

DISASSEMBL
Y

TRANSMISSION
CASE
DISASSEMBLY

DISASSEMBLY
OF
GEAR
ASSEMBLY

ADAPTER
PLATE
DISASSEMBLY

REAR
EXTENSION
DISASSEMBLY

INSPECTION

TRANSMISSION
CASE
AND
REAR

EXTENSION

BEARING

GEARS
AND
SHAFTS

BAULK
RING

SHIFTING
INSERT

01
L
SEAL

REAR

ENGINE
MOUNTING

INSULATOR

ASSEMBL
Y

FRONT
COVER

ASSEMBLY

TRANSMISSION

CASE
ASSEMBLY

REAR
EXTENSION
ASSEMBLY

ADAPTER
PLATE

ASSEMBLY

ASSEMBLY
OF
GEAR
ASSEMBLY

TRANSMISSION

ASSEMBLY

S
SPEED
TRANSMISSION

Model
fSSW60L

REMOVAL

INSTALLATION
MT
2

MT
3

MT
4

MT
5

MT
5

MT
5

MT
9

MT
9

MT
9

MT
9

MT
9

MT
9

MT10

MT10

MT10

MT10

MT10

MT10

MT10

MT10

MTll

MT
1
1

MT14

MT

16

MT17

MT18
DISASSEMBL
Y

TRANSMISSION
CASE

DISASSEMBLY

DISASSEMBLY
OF
GEAR
ASSEMBLY

ADAPTER
PLATE
DISASSEMBLY

REAR

EXTENSION
DISASSEMBLY

INSPECTION

TRANSMISSION
CASE
AND

REAR
EXTENSION

BEARING

GEARS
AND

SHAFTS

BAULK
RING

SHIFTING
INSERT

01
L
SEAL

REAR
ENGINE

MOUNTING

INSULATOR

ASSEMBLY

FRONT
COVER
ASSEMBLY

TRANSMISSION
CASE
ASSEMBLY

REAR
EXTENSION
ASSEMBLY

ADAPTER
PLATE
ASSEMBLY

ASSEMBLY

OF
GEAR

ASSEMBLY

TRANSMISSION
ASSEMBLY

SERVICE

DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPECTION
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

CORRECTIONS

SPECIAL
SERVICE

TOOLS
MT19

MT19

MT19

MT
22

MT
22

MT
23

MT
23

MT
23

MT
23

MT
23

MT
24

MT
24

MT
24

MT
24

MT
24

MT
24

MT
24

MT
24

MT
25

MT

29

MT31

MT31

MT32

MT

33

MT

34

MT

35

Manual

Transmission

4
SPEED
TRANSMISSION
Model

F4W60L

t

f

@

4

Y

0

f

@
@

jj
J
QW

i

6

i

l

16
Rear
cxtension
dust
cover

with
oil
seal

17

Top
detecting
switch
TM281A

6
Tran
smi
sion
case
a

mbly

7
Filler

plug

8

Adapter
plate

9
Breather

10

Bearing
retainer

11

Rear
extension
dowel

pin

12
Reverse

lamp
sWitch

13
Rear
extension

assembly

14
Drain

plug

15
Retum

spring
bushing

Fig
MT
l

F4W60L

TrarwniuionClOMJ
Components
Tighteni
torque
kg
m
ft
lb

@
1
0
0

1
6

7
to
12

@
2
0
to
3
0

14
to
22

@
0
1
to
1
0

5
1

to
1

2

@
1

6102
2

12
to
16

@
2
5
to
4

0
18
to
29

itJ
2
0
to
3
5

141025

@
2
5
to
4

0
18
to
29

I8i
2
0

to
3
5

14
to
25
1
Front

cover

2
Front
cover
oil

seal

3
Front
cover
O

ring

4
Front

cover

adjusting
shim

5

Welch

plug

c

@

r

TM093A

1

Main
drive

bearing

2
Main
drive

gear

3
3rd

top
synchronizer

4

3rd

gear
mainshaft

5
Mainshaft

6
2nd

gear
mainmaft

7
ht

2nd
synchronizer

8
1

It

gear
mainshaft

9
Mainshaft
bearing

10
Reverse
gear
mainshaft

11
Counter

gear
assembly

12
Idler
gear
assembly

Fig
MT
2
F4W60L
Transmi8aion

G
CompoMnla
I

I

I

MT
2

I
ht
2nd

fork
r

2

3rd

top
fork
rod

3
Reverse
fork
rod

4

Retaining

pin

5
I
t

2nd
shift

fork

6
3rd

top
shift
fork

7

Checking
ball

plug

8

Check
ban

spring

9
Check
ball

10
Interlock

plunger

11

S

topper
ring

12

Shift
rod
A
bracket

13
Reverse

shift
fork

14
Lock

pin

15

Striking
lever
Manual
Transmission

16

Striking
rod

17
Return

spring
plug

18
Reverse

check

spring

19
Return

pring

20

Plunger

21
D

ring

22
Stopper
pin
bolt

23

Striking
guide
assembly

24

Striking
guide
oil
seal

REMOVAL

To

dismount
transmission

from
the

car

proceed
as
follows

Disconnect

battery
ground
cable

2

Remove
console
box

and
detach

rubber
boots
if

so

equipped

3

Place
transmission
control
lever

in

neutral

position
and
remove
it

m

TM781

Fig
MT
4

Removing
Control
Lever
@

@

25
Control
lever

bushing

26

Expansion
plug

27
Control

pin
bushing

28
Control
arm

pin

29
Control
lever
o

Tightening
torque
kg
m
ft
lb

@
0
5
to

0
8
3

6
tn
5
8

@
1
3
to
1
7

9
to
12

Fig
MT
3
F4W60L
Tra11lmiBSion

Shift
Control

Components
TM094A

4
Jack

up
the

car
and

support
its

weight
on

safety
stands
Use
a

hy

draulic
hoist
or

open
pit
if
available

Make

sure
that

safety
is

insured

5

Disconnect
front
exhaust
tube

and

remove
bolt

securing
exhaust

mounting
bracket
from

exhaust
front

tube

side

6

Disconnect
wires
from

reverse

back

up
lamp
switch

7

Disconnect

speedometer
cable

from
rear
extension
At

the
same
time

removey

top
detecting
switch
if
so

equipped

8
Remove

propeller
shaft

Refer
to
Removal
Section
PO

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from
flow

ing
out

MT
3
9

Remove
clutch

operating
cylinder

from
transmission
case

10

Support
engine
by
placing
a

jack

under
oil

pan
with
a
wooden

block

used
between
oil

pan
and

jack

CAUTION

00
not

place
the

jack
under
the

oil

pan
drain

plug

11

Support
transmission
with
a

transmission

jack

12

Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

V

Fig
MT
5

Removing
Rear

1IIline

Mounting
Croamember
Manual

Transmission

13

Remove

starling
motor

14
Remove
bolts

securing
transmis

sion
to

engine
and

gusset

Then

support
the

engine
and

trans

mission
with

jacks
and
slide
trans
is

sion
rearward

away
from

engine
and

remove
from
the
car

CAUTION

Take
care
in

dismounting
trammission

not
to
strike

any
adjacent
parts
and

main
drive

gear

INSTAUATION

Install
the
transmission
in
the

re

verse
order
of

removal

paying
atten

tion
to
the

following
points

MT
4
I

Before

installing
cJean

mating

surfaces
of

engine
rear

plate
and

trans

mission
case

2

Before

installing
lightly

apply

grease
to

spline

parts
of

clutch
disc

and

main
drive

gear
And
also

apply

grease
to

moving
surfaces
of

control

lever

and

striking
rod

3
Remove
filler

plug
and
fill
trans

mission
with

recommended

gear
oil
to

the

level
of
the

plug
hole

Oil

capacity

1
3
liter

2
US

pt
2

Y

Imp
ptl

4

Apply
sealant
to
threads
of
filler

plug
and

install
fdler

plug
to
transmis

sion

case

IiJ
Tightening
torque

Filler

plug

2
5
to
4
0

klt
fll

18
to
29
ft

Ib

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I

Prior
to
disassembling
traiIsmis

sian

thoroughly
wipe
off
dirt

and

grease
from
it

2
Drain

oil

thoroughly

3

Remove
dust
cover
from
trans

mission

case

Remove
release

bearing
and
with

drawallever

4

Remove
reverse

lamp
switch
and

top
detecting
switch
if

equipped

5
Remove

speedometer

pinion
as

sembly

6
Remove

nut
and

stopper
pin
bolt

from
rear
end
of
rear
extension

TM783

Fig
MT
6

Removing
Nut
and

Stopper
Pin
Bolt

7

Remove
return

spring
plug
return

spring
reverse
check

spring
and

plunger
from
rear
extension

@

@

j

TM784

Fig
MT

7
Rt

moving
Return

Spring
Plug

8
Remove
front
cover
Detach

0

ring
and
front
cover

adjusting
shim

TM785

Fig
MT
B

Removing
Front
Cover

a

Ring
and

Adju

ting
Shim
Manual
Transmission

9
Remove
main

drive

bearing
snap

ring
with

snap
ring

pliers

o

TM188

Fig
MT

9
Rt

mouing
Main
Drive

BNring
Snap
Ring

10
Remove

rear
extenSion

secUring

baits
and
turn
the

striliing
rod

clock

wise

Drive
out
rear
extension

backward

by
lightly
ta

pping
around
it

with
a

soft

hammer

TM787

Fig
MT
10

Removing
Rear
Extemion

11

Separate
transmission
case
from

adapter
plate
by
evenly
tapping

around
it

with
a
soft
hammer

CAUTION

Do
not

pry
transmission
case
or
rear

extension
from

edapter
plate
with

screwdriver

TM788

Fig
MT
II

Removing
Tronsmiuion

COSf

MT

5
12

Set

up
Adapter
Setting
Plate

KV32100300

on

adapter
plate

Place
the
above

assembly
in

a
vise

TM789

Fig
MT
12
A

ttaching
Gear

A
mbly

to

Special
Tool

13
Detach
counter

gear
thrust

washer

DISASSEMBLY
OF

GEAR

ASSEMBLY

Shift

forks
and
fork
rods

I

Drive

out

retaining

pins
from

each
fork

rod
with
Fork

Rod
Pin

Punch

ST23540000

TM790

Fig
MT
13
Drive
Out

Retaining
Pim

2

Drive
out
reverse

gear
shift
fork

and
reverse
idief

gea

TM791

Fig
MT
14

Driving
Out
Re
1dkr

Gear
and

Shift
Fork

3

Remove
three
3
chick

ball

plugs

TM792

Fig
MT
15

Removing
Check
Ball

Plug

4

Drive
out
fork
rods
from

adapter

plate
by
lightly
tapping
on

the
front

end

Detach
shift
forks

Note

a
Be

careful
not
to
lose

three
3

check
balls
and

two
2
interlock

pluDgl
rs

b
Each

gear
and
sbaft
can
be
de

tached
from

adapter
plate
without

removing
each
fork
rod

D

t

@

@
6

@

1

q
eck
ball

ptug

2
Fork
Tod
1st
2nd

3
InterJock

plunger

4

Fork
rod
3rd
4th

5

Fork
rod
reverse

6
Check
ball
TM793

Fig
MT
16
Check
Ball
and

Interlock

Plunger

Gear

assembly

Note
It

is

necessary
to
measure
end

play
before

disassembling
main

sbaft
and
after

reassembling
main

shaft
Refer
to

Inspection
for
Gears

and
Shafts

1
Remove
reverse

gear

snap
ring

from
the

rear
of
mainshaft

using

snap

ring

pliers
and
remove
thrust
washer

and
mainshaft
reverse

gear
Manual

Transmission

TM794

Fig
MT

17
R

molJing
Reuerse
Gear

SfUJpRing

2

Remove
four
4

bearing
retainer

attaching
screws
with

an

impact
driver

and
remove

bearing
retainer

TM79S

Fif
MT

18

RemouingBcrews

3

Remove

snap

ring
from

mainshaft

rear

bearing
using

snap
ring
pliers

TM796

Fig
MT
19

Removing
Mainshaft
Rear

Bearing

Snap
Ring

4
Drive

out
mainshaft

gear
as

sembly
together
with
counter

gear

assembly
by
lightly
tapping
the
rea

end
with
a

soft
hammer
while

holding

the
front
of
mainshaft

gear
assembly

and
counter

gear
assembly
by
hand

MT
6
Remove

counter

g
ar

main

dfN

gear
and

mainshaft

assembly
in
that

order

CAUTION

Be
careful
not
to

drop
gears

TM797

Fig
MT
20

Removing
Gear

AlSembly

Malnshaft

Disassemble
mainsltaft

gear
assem

bly
as
follows

1
R

emove

snap
ring
from

l
l
Iinshaft

front
end

Remove
3rd

4th

synchronizer

assembly
baulk

rings
3r

gear
and

mainshaft
needle

bearing
toward
the

front
side

Fig
MT
21

Removing

Snap
Ring

2

Press

out
mainsltaft

bearing
using

Bearing
Puller

ST3003Iooo
See

Fig

MT
23

CAUTION

When

pressing
out

bearing
hold

main

shaft

by
hand
so
as
not
to

drop
it

Manual

Transmission

3
Remove
thrust
washer
1
st

gear

needle

bearing
bushing
1st
2nd

synchronizer
assembly
baulk

rings

2nd

gear
and
needle

bearing
from

mains
haft

ST30031000

l
l

TM693

Fig
MT
22

RemotJing
Mainshaft

Bearing

fJ

I

@

00
1

Snap
ring

2

Baulk

ring

3

Shifting
imcrt

4

Coupling
sleeve

5

3rd

gear
mainshaft

6
Needle

bearing

7

Mainshaft

8

Spread
spring

9

Synchronil
er
hub

10

3rd
4th

synchroniz
er
assembly
II
2nd

gear
mainshat
t

12
ht
2nd

synchronizer

assembly

13
Mainshaft

bearing

14
1st

gear
mainshaft

15

Bushing
ht

speed
gear

16
Thrust
washer
mainshaft

11
Reverse

gear
mainshaCt

18
Thrust
washer

19

Snap
ring

TM799

Fig
MT
23

Mainshaft

A
mbly

Remove

sna

p
ring
and

spacer
with

snap

ring
pliers

2
Press
out

main
drive

bearing
with

Bearing
Puller
ST22730000
and
a

suitable

press
CAUTION

When

pressing
oul

bearing
hold

gear

by
hand
so
as
not
to

drop
it

1
Mein
drive

geer

ST22730000

TM

695

Fig
MT
24

Removing
Main
Drive

Bearing

MT7

Manual
Transmission

1
Snap
ring

2

Spacer

3

MaiJl4rive
be

ng

4

Main
drive
gear

5
Pilot

bearing

TM696

Fig
MT
25
Main
Drive
Gear

Counter

gear

1
Remove

snap
ring
from
the

rear

of
counter

gear
using
snap
ring
pliers
2

Press
out

counter
reverse

gear

using
Bearing
Puller
ST22730000
and

suitable
bar

CAUTION

When

pressing
out
coiinter
reverse

gear
hold

gear
by
hand
so
as
not
to

drop
it

TM697

Fig
MT

26
Removing
Snap
Ring

@

5

i

MT
8
H

J

TM698

Fig
MT
27

Removing
Counter

Reverse
Gear

3
Press
out

counter

gear
rear
bear

ing
using
Bearing
Puller
ST22730000

CAUTION

Be
careful
01
to

drop
counter

gear

9

iL

TM699

Fig
MT
28

Removing
Counter
Gear

Rear

Bering

1
Needle

bearing

2

Thrust
washer

3

Counter

gear

4

Bearing

5

Counter
reverse

gear

6

Snap
ring

TM800

Fig
MT
29
Counter

Gear